Tag Archives: furler

The Final Rigging Repair Part III

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Our rigging work is almost complete. The last part of our rigging work is the replacement of our furler and foils. 

Our furler is 24+ years old and has been limping along for awhile.  We’ve known we would need to replace it but we were hoping to do so in New Zealand (in 2 months).

We assumed we would have more resources available to us in NZ as opposed to Fiji.  But, we’ve been pleasantly surprised.

What does a Furler do?

A furler is a mechanical system on a sailboat that rolls a sail around a stay or into a hollow mast or boom. Furlers allow us to safely and easily deploy, release, and stow the genoa from the cockpit.  This eliminates the need to go onto the deck.

Sugar Shack has a forestay rod that has a multi purpose.  Part of the furler package is 18m of foils which will go on the solid rod we use as a forestay.  The leach of the genoa sail (front end) is threaded through the foils to attach it to the forestay.  The foils turn which allows the sail to be deployed or furled. 

The shaft on the furler has worn down over the years causing the bearing to not sit properly. 

So, the furler still had a little “give” or “wobble” even though we replaced the bearing.  

Ordering the Furler

Matt wanted the C430 x 18m Profurl Furler: included link plates 55mm + SS locks C430 and a threaded pin DIA 25mm (63/64).  

We placed the order with Wichard Pacific in Australia on Friday morning. Both parcels arrived and cleared customs on Tuesday afternoon. Pretty darn impressive!

Removing the Old Forestay, Foils, and Furler

Sammy from Westside Rigging first loosened both of side stays.  This action will release tension on the mast and forestay.

Next, Sammy removed the furler (at the bottom by the bow). 

His assistant held the bottom end of the forestay where the furler is located.

Matt then sent Sammy up to the top of the mast to remove the upper portion of the forestay.

The forestay is very long – about 18 meters long. 

We had 3 people in 2 different dinghies and 2 people on board.  

Sammy slowly lowered the top of the forestay as I guided it past the port bow and down  to the dinghy. 

We slowly get the entire forestay off the boat and stretched between the two dinghies to get it to shore.

It took all of us several hours to remove the old foils (which wrap around the forestay rod). 

Evidently, our NZ rigger used 5200 (heavy-duty glue) to lock in the set pins.  The 5200 prevented us from removing the set pins and forced us to cut 3 of the foils in order to get them off.

We donated 6 of our 9 foils and their connectors to another cruiser.

Installing the New Furler and Foils

We received (9) 2 meters foils (18 meters long), connection brackets and our new furler.

Our forestay (headstay) is 12.7mm stainless rod measuring at 17.5 meters long. It is HUGE. 

We laid the forestay out on the grass and tied off the ends to allow us to pull it straight as we worked.

First the foils go on.  This can be tricky as they have to align just right to get on the rod. And on top of that they fit very snugly over the pin that at the end of the rod.

Sammy installed the connectors which connect the foils to each other.

Loctite is placed on the set pins which are used to secure the foils to the connectors.

The top portion of the furler is inserted and then it is time to work on the furler drum. 

The drum is partially installed and will be completed back on the boat. 

Took a bit of fiddling and maneuvering, but  we installed the headstay and new furler!  Yeah!

Our blog posts run 8-10 weeks behind actual live events. 

We replaced our furler toward the end of September 2025 in Vuda Marina, Fiji.

In our last blog, we share the experience of replacing our standing rigging side stays in Fiji.

Rigging Repairs & More Damage: Part II

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We noticed a problem with our standing rigging several weeks ago (see Part I Compromised Rigging).  Unfortunately, we were several days away from the closest marina so we had to “baby” our rig until we could replace it.

Vuda Marina

Westside Rigging works out of Vuda Point Marina. Prior to now, we had never had an opportunity to stay at Vuda – always a first for everything.

Our main goal is to replace the side stays and fix the furler so we get to work right away.

Removing the Side stays

Sammy and Theo from Westside Rigging arrived at 0900 and had both side stays off within 45 minutes.  

We decided to upgrade our side stays after learning that Sammy had stronger wire in stock.  So, instead of replacing the side stays with the same 16mm 1×19 wire we went with 34 meters, 16mm dyform 1×25 stainless wire which is 30% stronger! 

In addition, we decided to replace our old turnbuckles with new Regatta R/S stainless turnbuckles. 

I was cleaning the stainless a few hours before they came and encountered a problem.  I was cleaning the port lower gate, opened it, and it fell off in my hand!  For duck’s sake!  Seriously.  The lifeline sheared off right at the pin with no sign of corrosion, rust, or degradation. 

So, Westside Rigging took the port side lower gate to repair it as well.

New, Shiny Gear

Sammy was able to swage the pin at the top of each side stay and swage the stud at the bottom earlier that morning.  He returned to the boat the next day at 10am and had the side stays and the gate installed by 11am.  Super efficient

Not sure if you can tell the difference between the old and new side stays.  The new dyform has wire that is a little flatter where as the old wire is round. 

The image in the lower left corner shows the difference between the two wires as well.

The Furler ‘s Dead

Our ProFurl (NC43LCE) is original to the boat, 2001.  It has lasted a long time!  We thought we could replace the bearings and continue using it for a few more years.  

However, after the near bearings were installed the furler still had wiggle room.  It works, but the bearings will just wear out again with the extra wiggle room.

So, what does that mean?  We have to buy a new furler and while we are at it we will purchase new foils to go on the forestay rod.  Bleeding money here.

Westside rigging did not have this in stock so he connected us with Wichard Pacific in Australia.  We decided to order a Profurl C430 x 18mm furler along with link plates (55mm+ SS Locks C430) and Threaded pin DIA 25mm (63/64). 

The parcels arrived from Australia in less than 1 week.

Stay tuned for Part II: Replacing the Furler

Our blog posts run 8-10 weeks behind actual live events.  We were in Vuda replacing the side stays at the end of August 2025.

Don’t miss out on our blog post “Vatulele: Curiously delightful“

Failures Bring on Frustrating Times

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Sugar Shack has had a string of failures over the last few weeks. I cannot remember a time when I’ve been so frustrated.  

Our boat has been and continues to be an amazing vessel. 

She has safely transported us over 50,000nm across both the Atlantic and Pacific Oceans.  She is our home, our yacht, our love and I would not trade her for anything else.  We love our Catana!

However, with anything over 24 years old you have failures.  

All of this happened over the course of 2 weeks in route to Fiji from the Marshall Islands.

Double Steering Failure

As you might recall, we had a “A Double Steering Failure” when we lost our starboard steering gear box and our port rudder arm.  This rendered our starboard helm un-steerable and our port helm without a rudder. 

Makes steering a challenge, but still doable with auto pilot using the port steering gear box and the starboard rudder.

Problem: ​Starboard Steering Gear Box failed. 

Solution: We ordered new bearings and seals from Germany for both port and starboard.  They’re being sent to Fiji where we will do repairs.

Problem: Port Rudder Arm failed. 

Solution: The good news is it broke at the attachment point.  We found the one man who has the tools to weld stainless and he fixed our rudder arm! We need to weld the two pieces together at the exact correct length to reinstall the rudder arm.

Matt and I searched for a stainless welder all over Funafuti over 3 days.  We finally found the one man who has the tools and expertise.  He tack welded the two pieces together, then did some grinding, then finished the welding.  We are back in business with two rudders!

A Massive Disappointment

Port Engine Failure

Problem: Our port engine water pump had a slow leak.  We had been watching it and were prepared to replace it once we got to Fiji. However, the leak got progressively worse.  So, Matt decided to replace it in Tuvalu.

The water pump is located in front of the engine making it a challenge to access. Matt has to lean over the engine, upside down to access the pump. Many pieces and parts have to be removed including the timing belt.

Problem #2: As Matt was removing the timing belt it ripped!  Oh for the love of God!  The engine can’t run at all without a timing belt!  This is bad, very bad!

Solution: The water pump was installed, but there is nothing we can do about the timing belt.  We ordered (2) new timing belts (one for both engines) from the UK to be delivered to Fiji where we will do repairs.

More Annoying Issues

Problem:  As Matt was removing pieces from the engine to get to the water pump one of his most used sockets fell into the water.  We are in 14m depth (40′).  

We got the dive gear out and both pressure gauges had water ingress and were not readable. 

Solution:  Matt used the dive gear anyway and within 4 minutes found the socket!  Yeah.

Problem: The furler is starting to fail and is leaking.  It is still working, but we have to be gentle when using the genoa.

Solution: We ordered new bearings and seals to be sent to Fiji where we will do repairs.

Problem: The washdown pump failed.  We use this pump to hose off the boat and clean the ground tackle (with both fresh and salt water).

Solution:  Matt thought we could just take it a part, clean it and get it working.  But this 13 year old pump was done.  We will have to buy a new one.

Summary

 
We have one engine and one rudder forcing us to run between helm stations. And somehow make it to Fiji to do the repairs.
 
Good news:  
  • We can steer from the Port helm and run back to starboard to use the throttles
  • We found a stainless welder in Tuvalu (the 2nd smallest country in the world). We now have use of both rudders
  • The port engine NEW water pump is installed
  • The engine was off when the timing belt failed.
    • Would have been catastrophic if it failed with the engine on.
  • We found the socket in 14m of silty water.  New octopi will be purchased in the future
  • Matt thinks he can take the washdown pump apart, clean it, service it and get it working without a replacement.  
  • The furler still works but we have to be gentle using it.  

Trying our best to see the silver lining. We are truly blessed and know that “life happens.”  It’s just hard when it happens all at one time.

We find some joy and charm in Tuvalu – check out our last blog post.

Our blog posts run 8-10 weeks behind actual events.  The failures occurred between mid to end of March 2025.